Part size - Smaller foam molded products are often not economical to produce. We suggest minimum part sizes be greater than 2 square inches. Larger sizes can be up to 30” by 26” by 14” with a maximum weight of 2,800 grams.

Tolerances - Since PopFoam is a soft compound that expands from tooling, many factors influence the amount of tolerance required. We will work with you to develop a process control plan.

Parting line – Our engineers will help you to determine the optimum locations for the parting line and gate locations as it relates to the part’s appearance and production.

Wall sections – Though common wall sections range from .25” to .6”, they can be as wide as 2”.

Texture, Text and Logos - PopFoam can accommodate a wide variety of subtle shapes that either rise from, or recess into, the body of the part.

Exactly What You Expect

Materials – Because foam injection molds don’t experience the same pressures, they can be made from aluminum, which is less expensive than the traditional material: hardened steel. The aluminum acts as an excellent heat transfer in our process.

Dependable Manufacturing

With the molds completed, we apply decades of industry experience to manage the precise production of your foam molded products.

How Injection Molded Foam Works

The exact blend of compounds selected for your product’s properties are poured as pellets into hoppers.

The pellets are melted and injected into your product’s mold. The heat transferred through the mold to the compound cross links the foam and cooks it. This is modern-day magic: the precise combination of compounds bind together in a miniature version of your product.

The mold separates at an accelerated speed, allowing the foam to burst out, and expand rapidly.

To ensure your product retains the expected size and shape, the new foam product is placed in a fixture to cool to the correct dimensions.

The result: complete reliability. PopFoam’s experienced team oversees each step of the foam molding process, so we can exceed your expectations.